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GB/T 16507.8-2022 English PDF (GBT16507.8-2022)

GB/T 16507.8-2022 English PDF (GBT16507.8-2022)

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GB/T 16507.8-2022: Water-tube boilers - Part 8: Installation and operation

This document specifies the requirements for the installation, commissioning, quality inspection and operation of the water-tube boiler proper and the piping within the scope of the boiler. This document applies to water-tube boilers defined in GB/T 16507.1. The transformation and repair of water-tube boilers can use this document as reference.
GB/T 16507.8-2022
GB
NATIONAL STANDARD OF THE
PEOPLE REPUBLIC OF CHINA
ICS 27.060.30
CCS J 98
Replacing GB/T 16507.8-2013
Water-tube boilers - Part 8: Installation and operation
ISSUED ON: MARCH 09, 2022
IMPLEMENTED ON: OCTOBER 01, 2022
Issued by: State Administration for Market Regulation;
Standardization Administration of the People's Republic of China.
Table of Contents
Foreword ... 3
Introduction ... 8
1 Scope ... 10
2 Normative references ... 10
3 Terms and definitions ... 11
4 Basic requirements ... 11
5 Foundation, support (structure) frame and steel structure ... 15
6 Drum, start-up (steam water) separator, water storage tank and header, desuperheater ... 21
7 Heating surface ... 25
8 Air preheater ... 32
9 Boiler proper piping and piping within boiler range ... 37
10 Safety accessories and instruments ... 39
11 Combustion device ... 44
12 Auxiliary devices ... 48
13 Platforms, escalators, railings ... 49
14 Hydrostatic test ... 49
15 Furnace wall masonry, pouring and insulation ... 51
16 Chemical cleaning, flushing and purging ... 52
17 Conditioning ... 55
18 Quality acceptance ... 56
19 Operation ... 57
Annex A (informative) Allowable deviation of fire grate installation for layer-fired boilers ... 61
Bibliography ... 63
Water-tube boilers - Part 8: Installation and operation
1 Scope
This document specifies the requirements for the installation, commissioning, quality inspection and operation of the water-tube boiler proper and the piping within the scope of the boiler.
This document applies to water-tube boilers defined in GB/T 16507.1. The transformation and repair of water-tube boilers can use this document as reference. 2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. GB/T 1576, Water quality for industrial boilers
GB/T 2900.48, Electrotechnical terminology of boilers
GB/T 12145, Quality criterion of water and steam for power plant and steam- generating equipment
GB/T 16507.1, Water-tube boilers - Part 1: General requirements
GB/T 16507.4, Water-tube boilers - Part 4: Strength calculation of pressure parts GB/T 16507.6, Water-tube boilers - Part 6: Inspection, testing and acceptance GB/T 16507.7, Water-tube boilers - Part 7: Safety appurtenances and instruments GB 50016, Code for Fire Protection Design of Buildings
GB 50041, Standard for design of boiler plant
GB 50204, Code for quality acceptance of concrete structure construction GB 50205, Standard for acceptance of construction quality of steel structures GB 50273, Standard for construction and acceptance of boiler installation engineering
GB 50275, Code for construction and acceptance of fan, compressor and pump installation
DL/T 777, Boiler refractory material for thermal power plant
DL/T 852, Guide of boiler start-up commissioning
DL/T 902, Abrasion resistant refractory material
NB/T 47013 (all parts), Non-destructive testing of pressure equipment
3 Terms and definitions
The terms and definitions defined in GB/T 2900.48 and GB/T 16507.1 as well as the followings apply to this document.
3.1 commissioning
A general term for that boilers and related equipment and systems are adjusted, calibrated and tested in accordance with the design and equipment technical documents after installation.
NOTE: Commissioning is short for adjustment and test.
3.2 commissioning of individual equipment and system
Dynamic inspection and test for a single piece of equipment or system.
3.3 start up and commissioning
On the basis of completing the commissioning of individual equipment and system, the start-up commissioning that is jointly participated by commissioner, producer and constructer to carry out the joint electrical and thermal automation of the complete set of steam turbine and boiler equipment.
4 Basic requirements
4.1 The location and building where the boiler is installed shall meet the relevant regulations of GB 50016 and GB 50041 and meet the requirements of the design drawings. The installation position of the piping within the boiler range shall keep a sufficient safe distance from crowded places (such as control room, duty room). When the safety distance requirements cannot be met, the building shall take necessary explosion-proof and isolation measures.
4.2 Boiler installation shall be carried out after the basic civil work is completed and accepted.
4.3 Before installing all parts of the boiler, relevant technical documents and quality 4.13 During the installation and construction process, it is not allowed to smash holes on building components, damage load-bearing components, or perform welding construction on component reinforcements without structural checks.
4.14 During the installation and construction process, measures shall be taken to prevent noise, dust, arc light and radiation pollution. Reduce construction waste discharge. 4.15 During the boiler installation process, the constructer shall implement the requirements of the quality assurance system. Accept the supervision and inspection of the establishment and operation of the quality assurance system by the inspection agency as well as the supervision-inspection of items related to safety performance. 4.16 During the boiler installation process, the constructer shall conduct non- destructive testing on the welded joints of boiler pressure elements and components in accordance with NB/T 47013 and meet the following requirements.
a) The testing method shall be selected according to the design, process and technical conditions. Develop a corresponding testing process. If multiple non-destructive testing methods are used for testing, they shall be evaluated according to their respective acceptance standards. The non-destructive testing can be considered as accepted only after all the tests are accepted. When the time-of-flight diffraction method (TOFD) is selected, it shall be combined with the pulse-echo method (PE) for testing. The testing conclusion is judged comprehensively based on the results of TOFD and PE methods.
b) The non-destructive testing of welded joints shall be carried out after the shape, size and appearance quality inspection is accepted. Materials with a tendency to delayed cracking shall be subjected to non-destructive testing 24h after welding. Welded joints prone to reheat cracking shall be retested by surface non- destructive testing after final heat treatment.
c) The technical level of non-destructive testing and the quality level of welded joints meet the following requirements:
1) During magnetic particle testing, the quality level shall not be lower than level I.
2) During penetrant testing, the quality level shall not be lower than level I. 3) Radiographic testing technology level shall not be lower than level AB. The quality level of welded joints shall not be lower than level II.
4) The technical level of pulse echo ultrasonic testing and phased array ultrasonic testing shall not be lower than level B. The quality level of welded joints shall not be lower than level I.
5) The ultrasonic testing technology level of diffraction time-of-flight method shall not be lower than level B. The quality level of welded joints shall not be lower than level II.
4.17 During boiler installation, the requirements for rework and post-repair inspection of welded joints of pressure elements and components are as follows:
a) When the welded joints of the pressure elements are found to have excessive defects after inspection, the constructer shall find out the reasons. Make a feasible rework plan before rework can be carried out.
b) Defects shall be completely removed before rework welding.
c) Rework welding at the same position shall not exceed 2 times. If it is more than 2 times, it shall be approved by the technical director of the constructer. d) After repair welding, the repair welding area shall be subjected to visual inspection and non-destructive testing of the same non-destructive testing process. For welded joints requiring post-weld heat treatment, final non-destructive testing shall be carried out after heat treatment is completed.
4.18 Boilers shall be equipped with necessary pressure, temperature, water level measuring devices and alarm devices, boiler overpressure interlock protection devices, water level overrun interlock protection devices, furnace pressure monitoring and protection devices, and ignition program control and flameout protection devices. 4.19 The installation and construction of auxiliary equipment such as boiler blower, induced draft fan, feed water pump and circulating water pump shall meet the requirements of GB 50275.
4.20 Boilers shall be equipped with water treatment equipment that meets boiler feed water requirements as well as necessary water vapor sampling and quality monitoring devices and systems. For boilers with rated working pressure not less than 9.8MPa, continuous monitoring of water vapor quality shall also be realized.
4.21 After the installation of the boiler is completed, the pressure elements, components and main connecting tubes of the boiler proper and the tubes within the boiler range shall be cleaned and flushed. Power plant boilers generally need to be purged. 4.22 After the boiler installation is completed, the overall tightness test (or air leakage test) shall be carried out. Check the tightness of the furnace and flue gas duct. 4.23 Operations during boiler commissioning shall be carried out by operators who have been trained and have obtained corresponding special equipment operator certificates under the supervision and guidance of commissioning personnel. a) The slope is not less than 0.2%.
b) The expansion is free and does not hinder the thermal expansion of the drum, header and piping.
c) The exhaust air duct leads to a special emptying place.
d) Sewage and drainage pipes with different pressures are not connected to the same pressure-bearing piping.
e) For drainage pipes that may form a closed-circuit during operation, the selection of the pressure level is the same as that of the connecting pipes.
f) When the upstream design pressure of the piping is greater than 3.8MPa, at least two valves connected in series shall be installed in the piping. At least one of the valves is close to the outlet of the piping.
9.1.9 The piping support and hanger shall be arranged reasonably. The structure shall be firm. It can not only meet the support and expansion requirements of the piping load, but also avoid deformation and vibration of the piping due to insufficient restraint. 9.2 Piping elements
9.2.1 A check valve and a cut-off valve shall be installed at the outlet of the feed water pump. A feed water check valve shall be installed between the feed water pump and the feed water cut-off valve. It is also closely connected with the water supply cut-off valve. The inlet of the economizer of the unit may not be equipped with a cut-off valve, a check valve and a main pipe water supply system. Each boiler economizer inlet shall be equipped with cut-off valve and check valve. The outlet of the cast iron economizer shall also be equipped with a shut-off valve and a check valve.
9.2.2 For the piping within the scope of the boilers operated by the main pipe, no less than two isolation valves with cut-off function shall be installed between every two boilers on the main pipe.
9.2.3 The installation position of the valve and its transmission device shall be convenient for operation and maintenance. Pay attention to the flow direction of the medium when installing the valve. It is not advisable to install the valve backwards. 9.2.4 The installation of the valve actuator shall meet the following requirements: a) Correctly adjust the limit switch position according to the characteristics of the actuator. Ensure that the valve can open and close in full stroke.
b) The torque protection test has been done according to the equipment technical documents. When the specified torque is exceeded, the protection can operate reliably.
9.2.5 The setting and installation of sewage discharge and water discharge devices shall meet the following requirements:
a) Drainage valves are required to be installed at the bottom of steam boiler drum, vertical boiler bottom ring and water circulation system. Use quick-open blowdown valves for boilers with rated working pressure less than 3.8MPa. The nominal diameter of the blowdown valve is 20mm~65mm.
b) For steam boilers with rated evaporation greater than 1t/h and hot water boilers with rated working pressure less than 3.8MPa and outlet water temperature greater than 120??C, install two valves in series on the sewage pipe. At least one of them is a blowdown valve, and it is installed on the side close to the outlet of the blowdown pipeline.
c) Install a drain valve at the lowest header (or pipeline) of the superheater system, reheater system, and economizer system.
d) The steam boiler drum with superheater needs to be equipped with continuous sewage discharge device.
e) Each boiler is equipped with an independent sewage pipe. Reduce the number of elbows when arranging the sewage pipes, so as to ensure smooth sewage
discharge and connect to a safe place or to the sewage expansion tank (expansion vessel).
f) When multiple boilers share one discharge main pipe, technical measures shall be adopted to prevent more than two boilers from discharging sewage at the same time.
g) Boiler blowdown valves and blowdown pipes shall not be threaded.
10 Safety accessories and instruments
10.1 Safety valve
10.1.1 The safety valve shall be installed vertically at the highest position of the drum and header. Exhaust pipes with sufficient cross section shall be installed. Between the safety valve and the drum or between the safety valve and the header, there shall be no pipelines and valves for taking steam or hot water.
10.1.2 When installing a spring safety valve with threaded connection, it shall be connected with a short pipe with thread. The connection between the short pipe and the drum or header shell shall be welded.
10.1.3 When multiple safety valves need to be installed on the same piping connected to the drum or header, the flow area of the piping shall not be less than the sum of the moving parts that may change its set pressure.
10.1.11 Control-type safety valves (including forced exhaust valves) shall be subjected to control circuit reliability test and opening performance test respectively. 10.2 Water level measurement and display control device
10.2.1 The water level gauge (direct-reading type) shall be installed in a place that is convenient for observation and operation. When the vertical distance between it and the operating plane of the boiler is higher than 6m, a remote water level measuring device and a water level TV monitoring system shall be installed.
10.2.2 The drum of each pressure level of waste heat boiler with multiple pressure levels shall be equipped with two independent water level gauges (direct-reading type). 10.2.3 There shall be at least two reliable remote water level measuring devices in the boiler control room. The signals shall be able to be taken out independently. The water storage tank and the start-up (steam-water) separator in the start-up system of the DC steam boiler shall be equipped with a remote water level measurement device. 10.2.4 The water level gauge (direct-reading type) and the steam side connecting pipe of the drum shall be inclined to the direction of the water level gauge. The water side connecting pipe shall be inclined to the direction of the drum. When the steam-water connecting pipe needs to be provided with a bracket, it shall be installed independently of the drum. It shall not hinder the thermal expansion of the connecting pipe. 10.2.5 Water level gauge (direct-reading) steam-water connecting pipe shall be insulated according to the requirements of the drawing. The balance container shall be insulated strictly according to the heat insulation method of the design drawing to ensure that the condensation section can be fully cooled.
10.2.6 The water level gauge (direct-reading type) shall be based on the center line of the drum after installation. At least mark the normal, high and low water level lines on the water level gauge. The deviation shall not be greater than 1mm. When installing a boiler water level gauge with a rated working pressure greater than 9.8MPa, the measurement error caused by the difference in density between the water level gauge and the liquid in the drum shall be corrected.
10.2.7 The steam and water connecting pipes of the water level gauge (direct-reading type) shall be equipped with quick shut-off valves. When electric valves are used as quick shut-off valves, explosion-proof electric actuators shall be selected. For boilers with rated evaporation less than 0.5t/h, valves may not be installed on the steam-water connecting pipe between the water level gauge and the drum.
10.2.8 Water level gauge (direct-reading) glass pressure plate and mica sheet cover joint surface shall be sealed with copper gasket. The sealing surface shall be flat and tight. If necessary, it shall be installed after grinding. The direct-reading water level gauge only conducts the working pressure hydrostatic test. It does not participate in the boiler proper hydrostatic test.
10.2.9 The mica sheet, glass plate and quartz glass tube used in the water level meter (direct reading type) shall meet the following requirements:
a) The mica sheet is transparent, straight and uniform, without spots, wrinkles, cracks, bends and other defects.
b) The thickness of the mica sheet is selected according to the steam pressure at the working position of the water level gauge. When the working pressure is less than 9.8 MPa, the total thickness is 0.8mm~1.0mm. When the working pressure is not less than 9.8MPa, the total thickness is generally 1.2mm~1.5mm.
c) The compressive strength and thermal stability of the glass plate and quartz glass tube meet the requirements of the steam pressure at the working position. The sealing surface is good.
10.3 Pressure measuring device
10.3.1 Pressure gauges shall be installed at the following parts of the boiler: a) the steam space of the steam boiler drum;
b) in front of the water supply regulating valve;
c) economizer outlet;
d) between superheater outlet and main steam valve;
e) reheater outlet and inlet;
f) on the start-up (steam-water) separator of the DC steam boiler or its outlet pipe; g) DC steam boiler economizer inlet, water storage tank and circulation pump outlet; h) in front of the shut-off valve at the outlet of the evaporating heating surface of the DC steam boiler (if a shut-off valve is installed);
i) on the drum of the hot water boiler;
j) the outlet of the water inlet valve and the inlet of the water outlet valve of the hot water boiler;
k) the outlet and inlet of the circulating water pump of the hot water boiler; l) the oil pump inlet (oil return) and outlet of the ignition oil system of oil-fired boilers and coal-fired boilers;
combustion devices shall also meet the following requirements:
a) An appropriate expansion gap is reserved between the secondary air baffle door and the air shell.
b) Th...

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